Wadding

ABSTRACT

Wadding of the present invention is obtained by mixing 20% by mass or more and 95% by mass or less of an acrylic fiber and 5% by mass or more and 80% by mass or less of a polyester fiber, in which a down power is 140 cm3/g or more and 300 cm3/g or less, and a warmth retention property (Clo value) is 3.7 or more and 5 or less.

The present application is a continuation application of InternationalApplication No. PCT/JP2016/081078, filed on Oct. 20, 2016, which claimspriority to Japanese Patent Application Nos. 2015-206232 and2015-206233, filed on Oct. 20, 2015, the contents of which areincorporated herein by reference.

TECHNICAL FIELD

The present invention relates to a wadding used for an application suchas a down jacket or bedding such as a comforter.

BACKGROUND ART

It is known that down mainly used as a wadding for bedclothes andbedding, down jackets, and the like has a rich texture and islightweight, has excellent warmth retention property and bulkiness, andfurther has a high recovery rate after compression. However, in order toobtain the down, not only is it necessary to breed a lot of waterfowland a large amount of a feed is required, but also there are problems ofwater contamination due to excreta of the waterfowl, occurrence ofinfection, and spread of the infection. In addition, in order to enablethe down to be used as a wadding, it is necessary to go through manysteps of plucking of down, selection, disinfection, and fat removal.Further, since the down is blown up during the steps, working becomescomplicated. Accordingly, a cost of bedclothes and bedding using thedown as a wadding is high.

In addition, as a material of the wadding, it is also possible to use apolyester fiber. The polyester fiber is low-cost but there are problemsin that lightweightness and bulkiness are not sufficient and the warmthretention property is low.

Therefore, it has been attempted to impart bulkiness to a syntheticfiber such as the polyester fiber.

For example, in PTL 1, it is proposed that a certain amount of a surfacetreatment agent including a polyether-ester based block copolymer as amain component be attached to surfaces of both fibers of a matrixforming a fiber structure body and a heat-bonding short fiber to obtaina hard cotton structure body in which stiffness and elasticity areimproved. However, in the hard cotton structure body disclosed in PTL 1,stiffness is high but, accordingly, there is lack of flexibility, and itis not suitable for applications where good body-fit is required such asa comforter or a jacket.

In addition, PTL 2 proposes the wadding formed by laminating a layerincluding a fiber having single fiber fineness of 1.5 denier or less anda layer including a fiber having single fiber fineness of 2.5 to 15denier. However, in the wadding disclosed in PTL 2, the layer (web) of afiber having small single fiber fineness and the layer (web) of a fiberhaving large single fiber fineness are just laminated and a fiber havingdifferent fineness is not intertwined. Therefore, even when using fibershaving two different fibers, there is almost no effect of increasing thebulkiness. Here, “web” means a sheet-like object formed by superimposingfibers.

Further. PTL 3 proposes the wadding formed by mixing a short fiberhaving single fiber fineness of 0.5 dtex or more and less than 3 dtex, ahollow fiber of 5 dtex or more and less than 10 dtex, a hollow fiber of10 dtex or more and less than 30 dtex, and a heat-bonding short fiber of1 dtex or more and less than 5 dtex. In the wadding of PTL 3, warmthretention property is imparted by a short fiber of 0.5 dtex or more andless than 3 dtex and warmth retention property and bulkiness areimparted by a short fiber of 5 dtex or more. However, even in thewadding described in PTL 3, the bulkiness was not sufficient.

PTL 4 proposes ball-like cotton in which single fiber fineness is 1.1 to15.0 dtex, an average diameter obtained by intertwining fibers of whichlengths are 3 to 64 mm is 3 to 10 mm, and polyester fibers havingdifferent melting points include two or more kinds of heat-bondingfibers.

In the ball-like cotton of PTL 4, the fibers are partially bonded toeach other by heat-bonding fibers, thereby maintaining the shape andpreventing the wadding from biasing. However, even in the ball-likecotton disclosed in PTL 4, the bulkiness and the warmth retentionproperty were not sufficient.

CITATION LIST Patent Literature

[PTL 1] Japanese Unexamined Patent Application, First Publication No.2006-207110

[PTL 2] Japanese Unexamined Patent Application First Publication No.S56-143188

[PTL 3] Japanese Unexamined Patent Application. First Publication No.2013-177701

[PTL 4] Japanese Unexamined Patent Application First Publication No.2002-30555

SUMMARY OF INVENTION Technical Problem

The present invention solves the problems in the related art describedabove, and provides the wadding which has excellent bulkiness andflexibility and can be appropriately used for an application such as adown jacket or bedding such as a comforter.

Solution to Problem

A wadding of the present invention is obtained by mixing 20% by mass ormore and 95% by mass or less of an acrylic fiber and 5% by mass or moreand 80% by mass or less of a polyester fiber, in which a down power is140 cm³/g or more and 300 cm³/g or less, and a Clo value is 3.7 or moreand 5.0 or less.

In the wadding of the present invention, it is preferable that singlefiber fineness of the acrylic fiber be 0.1 dtex or more and 10 dtex orless, and single fiber fineness of the polyester fiber is 1 dtex or moreand 10 dtex or less.

In the wadding of the present invention, it is preferable that thepolyester fiber be a hollow fiber.

In the wadding of the present invention, it is preferable that a hollowratio of the hollow fiber be 10% or more and 30% or less.

In the wadding of the present invention, it is preferable that the downpower be 140 cm³/g or more and 220 cm³/g or less.

In the wadding of the present invention, it is preferable that the downpower be 160 cm³/g or more and 200 cm³/g or less.

In the wadding of the present invention, it is preferable that the Clovalue be 3.8 or more and 4.8 or less.

In the wadding of the present invention, it is preferable that the Clovalue be 4 or more and 4.7 or less.

In the wadding of the present invention, it is preferable that thesingle fiber fineness of the acrylic fiber be 0.5 dtex or more and 2.2dtex or less and the single fiber fineness of the polyester fiber be 1.7dtex or more and 2.2 dtex or less.

In the wadding of the present invention, it is preferable that a fiberlength of the acrylic fiber be 15 mm or more and 40 mm or less and afiber length of the polyester fiber be 10 mm or more and 40 mm or less.

In the wadding of the present invention, it is preferable that a mixingratio of a heat-bonding short fiber with respect to the wadding be 5% bymass or more and 30% by mass or less, and at least a part of theheat-bonding short fiber be bonded to the acrylic fiber or the polyesterfiber.

In the wadding of the present invention, it is preferable that 30% bymass or more and 70% by mass or less of the acrylic fiber having thesingle fiber fineness of 0.1 dtex or more ans 10 dtex or less beincluded, and the wadding be granular wadding in which one or aplurality of fibers are intertwined.

In the wadding of the present invention, it is preferable that 30% bymass or more and 70% by mass or less of the polyester fiber having thesingle fiber fineness of 1 dtex or more and 10 dtex or less be included.

In the wadding of the present invention, it is preferable that thepolyester fiber be a conjugate fiber and has a coil-like form in ano-load state.

In the wadding of the present invention, it is preferable that themaximum length of the granular wadding be 2 mm or more and 20 mm orless.

In the wadding of the present invention, it is preferable that thenumber of crimps of the acrylic fiber be 3 peaks/25 mm or more and 20peaks/25 mm or less.

In the wadding of the present invention, it is preferable that adecreasing rate of the down power after washing 10 times be 30% orlower.

Advantageous Effects of Invention

According to the present invention, it is possible to provide a waddingwhich has excellent bulkiness, flexibility, and warmth retentionproperty and can be appropriately used for an application such as a downjacket or bedding such as a comforter.

DESCRIPTION OF EMBODIMENTS

Hereinafter, the present invention will be described in detail.

The wadding of the present invention is obtained by mixing 20% by massor more and 95% by mass or less of an acrylic fiber and 5% by mass ormore and 80% by mass or less of a polyester fiber, in which a down poweris 120 cm³/g or more and 300 cm³/g or less, and a Clo value is 3.7 ormore and 5 or less.

In terms down quality, a down power grade is used as an index ofbulkiness. In the Japan down products corporative association, the gradeis classified into four ranks from a premium gold label of the highestquality, a royal gold label, an excel gold label, and a new gold label.The term “down power” indicates a volume per unit mass and representsthat the larger the value thereof, the higher the bulk. Examples of amethod for measuring the down power include a method in accordance withJIS L1903.

The wadding of the present invention makes it possible to providewarmth, lightness, and a similar texture to down by including theacrylic fiber, and has excellent recovery after compression by includingthe polyester fiber. The acrylic fiber and the polyester fiber aremixed, thereby increasing the bulkiness. It becomes possible to achieveboth improvement of warmth retention property and improvement ofrecoverability after compression.

That is, when 20% by mass or more and 95% by mass or less of the acrylicfiber and 5% by mass or more and 80% by mass or less of the polyesterfiber combine, it is possible to obtain a down power of 140 cm³/g ormore.

When the acrylic fiber is included in an amount of 20% by mass or morewith respect to the entire wadding, it is possible to further increasethe down power compared with a polyester 100% product and the warmthretention property is improved. When the acrylic fiber is 95% by mass orless, the polyester fiber is included in an amount of 5% by mass or morewith respect to the entire wadding. Therefore, the recoverability aftercompression is further improved compared with an acrylic fiber 100%product.

From this viewpoint, the mixing ratio of the acrylic fiber to thewadding is more preferably 30% by mass or more and 90% by mass or lessand further preferably 50% by mass or more and 85% by mass or less.

The wadding of the present invention can be mixed with other fibers inaddition to the acrylic fiber and the polyester fiber, as long as thedown power and the Clo value satisfy the specified ranges.

From the viewpoints of the down power and the Clo value, a total amountof the acrylic fiber and the polyester fiber is preferably 90% by massor more and more preferably 100% by mass, with respect to the totalamount of the wadding.

In addition, in the wadding of the present invention, it is preferablethat, when the down power is 140 cm³/g or more, the wadding be bulkierthan inner wadding formed of 100% by mass of a polyester fiber so thatthe warmth retention property increases. In addition, when the downpower is 300 cm³/g or less, the bulkiness is sufficient and the volumeper mass can be reduced. Therefore, it is advantageous in terms oftransportation cost.

From the viewpoint of the warmth retention property, the down power ismore preferably 150 cm³/g or more and 280 cm³/g or less, and furtherpreferably 160 cm³/g or more and 200 cm³/g or less.

In the wadding of the present invention, a Clo value measured by themethod described in Examples which will be described later is 3.7 ormore and 5 or less.

When the Clo value is 3.7 or more, the wadding can be used as thewadding with good warmth retention property. When the Clo value is 5 orless, the warmth retention property equivalent to the down is obtained.Therefore, the Clo value is sufficient.

From the viewpoint of warmth retention property, the Clo value is morepreferably 3.8 or more and further preferably 4 or more.

In the wadding of the present invention, it is preferable that singlefiber fineness of the acrylic fiber be 0.1 dtex or more and 10 dtex orless, and single fiber fineness of the polyester fiber be 1 dtex or moreand 10 dtex or less.

It is preferable that the single fiber fineness of the acrylic fiber be0.1 dtex or more, from the viewpoint of processability of the waddingmanufacturing, and it is preferable that the single fiber fineness ofthe acrylic fiber be 10 dtex or less, from the viewpoint of increasingwarmth retention property and the texture not being hard. From thisviewpoint, the single fiber fineness is more preferably 0.5 dtex or moreand 2.2 dtex or less and further preferably 0.8 dtex or more and 2.8dtex or less.

In addition, it is preferable that the mixing ratio of the acrylic fiberto the wadding be 20% by mass or more, from the viewpoint of improvingthe warmth retention property, and it is preferable that the mixingratio be 95% by mass, from the viewpoint of improving the recoverabilityby adding the polyester fiber.

It is preferable that the single fiber fineness of the polyester fiberbe 1 dtex or more, from the viewpoints that effects of improving therecoverability and preventing permanent set (fatigue deformation) fromoccurring can be obtained and the bulkiness increases, and it ispreferable that the single fiber fineness be 10 dtex or less, from theviewpoint of increasing the warmth retention property and the texturenot being hard. From this viewpoint, the single fiber fineness of thepolyester fiber is more preferably 1.7 dtex or more and 2.2 dtex orless.

The single fiber fineness described in the present specification can bemeasured by a method in accordance with 8.5 in JIS L1015: 2010.

In addition, it is preferable that the polyester fiber be a hollowfiber. Since the polyester fiber is inferior in the warmth retentionproperty compared to the acrylic fiber, when a cross-sectional shapethereof is formed to be hollow, it is possible to secure immobile air.Further, when the polyester fiber is formed to have a hollow crosssection, a cross-sectional area becomes larger than that of a non-hollowfiber. Therefore, effects are achieved such that the rigidity of thefiber increases, the recoverability is improved, and permanent set isprevented from occurring.

The hollow ratio of the hollow fiber is preferably 10%/o to 30%. It ispreferable that the hollow ratio of the hollow fiber be 10% or more,because the heat retention rate is improved. From this viewpoint, thehollow ratio of the hollow fiber is preferably 10% or more and morepreferably 20% or more.

In the wadding of the present invention, it is preferable that the fiberlength of the acrylic fiber be 15 mm or more and 40 mm or less and thefiber length of the polyester fiber is 10 mm or more and 40 mm or less.

Here, the “fiber length” described in the present specificationindicates a length in a fiber axis direction. The fiber length describedin the present specification can be measured by a method in accordancewith C method of 8.4 of JIS L1015: 2010.

It is preferable that the fiber length of the acrylic fiber be 15 mm ormore, because processability in the manufacturing process of the waddingis favorable and the bulkiness is improved, and it is preferable thatthe fiber length be 40 mm or less, because the fibers are suppressedfrom intertwining with each other and the wadding can be prevented frombiasing. Further, from this viewpoint, the fiber length of the acrylicfiber is more preferably 25 mm or more and 38 mm or less.

It is preferable that the fiber length of the polyester fiber be 10 mmor more, because it is possible to reduce falling of the polyester fiberin the manufacturing process or from the wadding, and it is preferablethat the fiber length be 40 mm or less, because the fibers aresuppressed from intertwining with each other and the wadding can beprevented from biasing. Further, from this viewpoint, the fiber lengthof the polyester fiber is preferably 12 mm or more and 35 mm or less andfurther preferably 25 mm or more and 30 mm or less.

The acrylic fiber can be appropriately selected according to a targetedapplication or performance. The acrylic fiber may be obtained by, forexample, a method in which side-by-side type fibers are mixed to developself-crimpability, thereby improving the bulkiness of the wadding, amethod in which Y-shaped fibers are mixed so as to improve the bulkinessof the wadding and the warmth retention property, or a method in whichfibers having single fiber fineness of 0.8 dtex or more and 20 dtex orless are mixed. In addition, as the acrylic fiber, for example, fibersin which each function is imparted and the performance is improved bycombining an antibacterial fiber, a deodorant fiber, a hygroscopicheat-generating fiber, an optothermal fiber, and a flame retardantfiber. In addition, the fiber may be used alone, and two or more thereofmay be used in combination.

In addition, it is preferable that the wadding of the present inventioninclude a heat-bonding short fiber in an amount of 5% by mass to 30% bymass and at least a part of the heat-bonding short fiber is bonded tothe acrylic fiber or the polyester fiber, from the viewpoints ofbulkiness, compression recoverability, and easy retention of a formednep.

As the heat-bonding short fiber, it is preferable to use a short fiberformed of low melting point resin having a melting point of 100° C. to200° C. As these short fibers, specifically, it is preferable to use ashort fiber using low melting point polyester obtained by copolymerizingisophthalic acid, adipic acid, cyclohexane dicarboxylic acid, sebacicacid, or the like to polyethylene terephthalate or polybutyleneterephthalate, as a raw material. After developing the nep, to be acore, of the acrylic fiber, the heat-bonding short fiber is thermallybonded to a part of the acrylic fiber. Accordingly, the nep can beretained. However, since the acrylic fiber of the present inventionprovides effects such that the single fiber fineness is very small andthe formed nep is difficult to unravel, the heat-bonding short fiber maybe used according to an application requiring durability.

Next, the wadding of the present invention can have a configuration inwhich 30% by mass or more and 70% by mass or less of the acrylic fiberand 30% by mass or more and 70% by mass or less of the polyester fiberare mixed, and the wadding is granular wadding in which one or aplurality of fibers are intertwined.

Advantageous effects of the down include bulkiness, warmth retentionproperty, and independence unique to a down ball. Here, in a case ofmixed wadding in which two or more types of wadding are mixed, when thefiber length is long, entanglement between the fibers becomes large,which causes the wadding to bias. On the other hand, since in a casewhere the fiber length is short, the entanglement of the fibers becomessmall, it is effective for preventing the wadding from biasing but doesnot contribute to the bulkiness between fibers. In addition, in themixed-wadding type in which opened wadding is mixed, it is difficult toprevent the wadding from biasing. However, when the wadding has agranular form, it is possible to impart independence unique to the down.Further, since if the single fiber fineness is small, the number ofconstituents per unit weight increases, and the warmth retentionproperty increases.

In the configuration, it is preferable that the content ratio of theacrylic fiber with respect to the entire wadding be 30% by mass or moreand 70% by mass or less. It is preferable that the content ratio of theacrylic fiber with respect to the entire wadding be 30% by mass or more,from the viewpoint of favorable formability of the granular wadding, andit is preferable that the content ratio be 70% by mass or less, from theviewpoint of improvement of the warmth retention property. From theseviewpoints, the content ratio of the acrylic fiber with respect to theentire wadding is more preferably 40% by mass or more and 60% by mass orless, and further preferably 45% by mass or more and 55% by mass orless.

In addition, in the configuration, it is preferable that the contentratio of the polyester fiber with respect to the entire wadding be 30%by mass or more and 700/o by mass or less. The wadding includes thepolyester fiber; accordingly, the formability of the granular waddingimproves and even after compression, a shape of the granular waddingrecovers to a form close to a sphere. As the shape of the granularwadding is closer to a sphere, the gaps between the granular waddingbecome larger. The amount of immobile air increases as a whole and thewarmth retention property improves.

It is preferable that the content ratio of the polyester fiber withrespect to the entire wadding be 30% by mass or more, from the viewpointof the formability of the granular wadding, and it is preferable thatthe content ratio thereof be 70% by mass or less, from the viewpoint ofimprovement of the heat retention rate. From these viewpoints, thecontent ratio of the polyester fiber with respect to the entire waddingis more preferably 40% by mass or more and 60% by mass or less, andfurther preferably 45% by mass or more and 55% by mass or less.

The granular wadding described in the present specification representswadding in which one or a plurality of fibers are intertwined to form asphere. The sphere may be, for example, a shape like a rugby ball or thefiber may appear like a whisker, as long as it is possible to recognizea shape close to a sphere.

The granular wadding is, for example, a shape close to a pill generatedon a wool sweater.

It is preferable that the acrylic fiber have crimps, from the viewpointof forming granular wadding. The crimp in this case may be mechanicalcrimping or may develop self-crimpability as a side-by-side typecomposite fiber.

The acrylic fiber can be appropriately selected according to a targetedapplication or performance. For example, the acrylic fiber may have across-sectional shape having a projection portion on a long side of aflat cross section, Y-shaped cross-sectional shape, and the like. Inaddition, for example, antibacterial property, deodorant property,hygroscopic heat-generating property, optothermal property, and flameretardancy are imparted to the acrylic fiber. In addition, the acrylicfiber can be individually combined. The acrylic fiber may be used aloneand two or more thereof may be used in combination.

In the wadding formed of the granular wadding having the configuration,it is preferable that the polyester fiber be a conjugate fiber, and havea coil-like form in a no-load state. Here, in order to form the granularwadding, the crimp of the fiber is important. If there is no crimp, agrain is not formed. The polyester fiber has a coil-like form, wherebythe fibers are entangled with each other and it is possible tomanufacture granular wadding.

In addition, in the wadding formed of the granular wadding having theabove described configuration, it is preferable that the maximum lengthof the granular wadding be 2 mm or more and 20 mm or less. It ispreferable that the maximum length of the granular wadding be 2 mm ormore, because it is difficult for the user to feel the tactile sensationof the grain. In addition, it is preferable that the maximum length ofthe granular wadding be 20 mm or less, because it is possible to preventthe wadding from biasing. Further, the closer the shape of the grain(granular wadding) to a true sphere, the larger the air gap and the morethe immobile air. Therefore, the warmth retention property improves.

From the viewpoints, the maximum length of granular wadding ispreferably 5 mm or more and 15 mm or less, and further preferably 7 mmor more and 13 mm or less.

In addition, in the wadding formed of the granular wadding having theconfiguration, it is preferable that the number of crimps of the acrylicfiber be 3 peaks/25 mm or more and 20 peaks/25 mm or less.

If the number of crimps of the acrylic fiber is 3 peaks/25 mm or moreand 20 peaks/25 mm or less, granular wadding is easily formed andshape-keeping property is also favorable. From these viewpoints, thenumber of crimps of the acrylic fiber is more preferably 7 peaks/25 mmor more and 13 peaks/25 mm or less.

The unit of “peak” in the number of crimps means the number of crimpingtimes (a value obtained by dividing a total number of the mountain andvalley by 2). In addition, the number of crimps described in the presentspecification can be measured by a method in accordance with 8.12 of JISL1015: 2010.

In the wadding having the configuration formed of the granular waddingas described above, it is preferable that the down power (DP) be 120cm³/g or more and 270 cm³/g or less. The down power of the waddingformed of the granular wadding is preferably 120 cm³/g or more, from theviewpoint of securing sufficient warmth retention property, morepreferably 130 cm³/g or more, and further preferably 140 cm³/g or more.

Further, in the wadding having the configuration formed of the granularwadding, it is preferable that the decreasing rate of the down powerafter washing 10 times be preferably 30% or lower. In general, the downhas restrictions on washing conditions such as dry cleaning and cannotbe washed at home, and is troublesome to handle. However, according tothe granular wadding of the present invention, the particle shape doesnot collapse even after washing and the granular waddings are notentangled with each other. Therefore, wadding biasing or lowering of thebulkiness is smaller than mixed wadding.

That is, in the wadding formed of the granular wadding, it is preferablethat the decreasing rate of the down power after washing 10 times be 30%or lower because sufficient warmth retention property can be maintainedeven after washing.

Next, the manufacturing method of the wadding of the present inventionwill be described.

The wadding of the present invention can be manufactured by a methodincluding steps of laminating or mixing an acrylic fiber having singlefiber fineness of 0.1 dtex or more and 10 dtex or less and a polyesterfiber of 1.0 dtex or more and 10 dtex or less to pass through aspreading machine, and mixing the fibers after opening with blowing orat least one or more carding machines.

In addition, in a case where the wadding is formed into the granularwadding, further, the fibers are put into a device for manufacturing thegranular wadding.

The method of manufacturing the acrylic fiber having single fiberfineness of 0.1 dtex to 10 dtex is not particularly limited, and theacrylic fiber having the single fiber fineness can be manufactured by aknown manufacturing method.

For example, there is a method including a step (A) in which after apolyacrylonitrile copolymer is dissolved in dimethylacetamide to obtaina solution, the solution is discharged and solidified in an aqueoussolution of dimethylacetamide using a nozzle having a discharge port toobtain a coagulated fiber, and further including a step (B) in which thecoagulated fiber obtained in the step (A) is subjected to drawingtreatment by wet heat drawing or dry heat drawing, or both methods, iswashed in boiling water, and dried at a temperature of 100° C. to 200°C. after applying oil, and then mechanical crimping (two-dimensionalmountain-like shape) is imparted to obtain a fiber (ultra-fine fiber)having a single fiber fineness of from 0.1 dtex to 10 dtex.

In the manufacturing method, the ratio of the polyacrylonitrilecopolymer dissolved in dimethylacetamide with respect to the solution ispreferably 10% by mass to 30% by mass and more preferably 15% by mass to25% by mass.

In addition, a pore diameter of the discharge port of the nozzle ispreferably 0.010 mm to 0.080 mm from the viewpoint of obtaining a fiberhaving a desired fineness, and more preferably 0.015 mm to 0.060 mm.

In addition, the concentration of dimethylacetamide in thedimethylacetamide aqueous solution is preferably 10% by mass to 80% bymass from the viewpoint of favorable processability, and more preferably20% by mass to 60% by mass.

In addition, a magnification of drawing of the coagulated fiber ispreferably 2 times to 8 times from the viewpoint of increasing thestrength, and more preferably 3 times to 6.5 times.

Further, examples of method of manufacturing a short fiber from theultra-fine fiber obtained in the method include a method including acrimping step (1) of further imparting mechanical crimping using a heatrelaxation treatment and/or a crimper as needed and further includingstep (2) of cutting the acrylic fiber so that the length thereof is 15mm to 40 mm after the crimping step (1).

The crimping step (1) is preferably machine crimping using a crimper,and it is preferable that the number of crimps be 3 peaks/25 mm to 20peaks/25 mm, from the viewpoint of bulkiness.

It is preferable that the number of crimps of the acrylic fiber be 3peaks/25 mm or more, from the viewpoint of maintaining the shape of thewadding, and it is preferable the number of crimps thereof be 20peaks/25 mm or less, from the viewpoint processability in manufacturingof the wadding.

Further, in a case where the manufacturing method of the waddingincludes a step of bonding the heat-bonding short fiber to the acrylicfiber or the polyester fiber, it is preferable that the acrylic fiberobtained in the step (2) be mixed with the heat-bonding short fiber tofix the nep by heating to a temperature of 100° C. to 220° C.

EXAMPLES

Hereinafter, the present invention will be described in detail withreference to examples and comparative examples, but the presentinvention is not limited to the examples.

(Measurement of Single Fiber Fineness)

Single fiber fineness of an acrylic fiber and a polyester fiber wasmeasured in accordance with JIS L 1015: 2010. The results are shown inTables 1 and 2 below.

(Measurement Method of Down Power)

A down power of the wadding was measured in the same manner as themethod specified in JIS L1903, except that the treatment using the dryermethod and the steam method of pretreatment are not performed. Theresults are shown in Tables 1 and 2 below.

(Measurement of Maximum Length of Granular Wadding)

The maximum length of the granular wadding was measured using a caliper.

At this time, 30 samples were measured and the average value thereof wastaken as the maximum length thereof. The results are shown in Tables 1and 2 below.

(Measurement Method of Clo Value)

The warmth retention rate (Clo value) of the wadding was measured usingThermo Labo II and a dry contact method under the following conditionsand procedure. The results are shown in Tables 1 and 2 below.

1. The measurement was performed in a test room in which a roomtemperature of 22° C. and humidity of 60% were maintained.

2. A sample which is obtained by putting 10 g of the wadding into a 20cm square cushion cover (fabric: 100% cotton) was prepared.

3. The sample was set on a heating plate set at 32° C. using the KES-F7Thermo Labo 11 Tester (registered trademark) manufactured by Kato TechCo., Ltd.

4. A heat quantity a (W) dissipated through the sample was calculatedunder a windy condition of 30 cm/sec.

5. A heat quantity b (W) dissipated in a state where the sample was notset was calculated, and the Clo value was calculated by the followingequation.

Clo value=0.645/(1/heat quantity a−1/heat quantity b)

This represents that the higher the Clo value, the more warmth retentionproperty of the wadding. In Tables 1 and 2 below, “-” indicatesnon-measured.

For the Thermo Labo 11 and dry contact method, and Clo value, refer tothe following URL.

(A) Thermo Labo II Dry contact method (General Foundation Boken QualityEvaluation Institute)

http://www.boken.or.jp/service/clothing/functionality/warmth_keeping.html

(B) Clo value (General Foundation Kaken Test Center)

http://www.kaken.or.jp/guidance/functionality/thermal_mannequin.html

(Evaluating Method of Permanent Setting Property)

A height Amm of a loading disk was measured in accordance with JISL1903, and the height Bmm of the loading disk after 24 hours wasmeasured.

Then, a value calculated using this formula ([(A−B)/A]×100(%)), fromrespective heights A and B obtained by the measurement, was assumed as apermanent setting property (fatigue deformability), and was evaluatedaccording to the following criteria.

A (Excellent): Permanent setting property 95% or more

B (Favorable): Permanent setting property 85% or more and less than 95%

C (Inferior): Permanent setting property less than 85%

Example 1

A copolymer formed of 95% by mass of acrylonitrile and 5% by mass ofvinyl acetate was dissolved in dimethylacetamide such that theconcentration of the copolymer was 20% by mass. Thereafter, the solutionwas discharged into an aqueous solution including 50% by mass ofdimethylacetamide using a nozzle having a round discharge hole with ahole diameter of 0.045 mm and subjected to washing in boiling water andstretching to 4.5 times. Then, an oil agent was applied to be dried at atemperature of 150° C. Thereafter, a thermal relaxation treatment wascarried out and mechanical crimp of 12 peaks/25 mm was imparted using acrimper. A tow was cut such that a length of the single fiber was 38 mm.Accordingly, an acrylic short fiber in which a cross-sectional shape wasround and single fiber fineness was 0.8 dtex was obtained.

Thereafter, 60% by mass of the acrylic short fibers as a fiber 1 and 40%by mass of the hollow polyester fiber (single fiber fineness: 2.2 dtex,fiber length: 20 mm, and hollow ratio 6%) as a fiber 2 were mixed with acotton mixing machine to pass through a spreading machine, and furthermixed with a carding machine to obtain the wadding.

Then, bulkiness evaluation and warmth retention property evaluation wereperformed using the wadding obtained by the method. The evaluationresults are shown in Table 1 below.

Example 2

The wadding was manufactured and evaluated by the same method as inExample 1 except that the fiber 2 was changed to a non-hollow regularpolyester having single fiber fineness of 1.7 dtex and a fiber length of15 mm. The results of bulkiness and warmth retention property obtainedin Example 2 are shown in Table 1 below.

Example 3

The wadding was manufactured and evaluated by the same method as inExample 1 except that proportions of the fibers 1 and 2 were changed asshown in Table 1 below. The results of bulkiness and warmth retentionproperty obtained in Example 3 are shown in Table 1.

Example 4

A copolymer formed of 93% by mass of acrylonitrile and 7% by mass ofvinyl acetate was dissolved in dimethylacetamide such that theconcentration of the copolymer was 20% by mass. Thereafter, the solutionwas discharged into an aqueous solution including 56% by mass ofdimethylacetamide using a nozzle having a round discharge hole with ahole diameter of 0.060 mm and subjected to washing in boiling water andstretching to 6 times. Then, an oil agent was applied to be dried at atemperature of 150° C. Thereafter, a thermal relaxation treatment wascarried out and mechanical crimp of 12 peaks/25 mm was imparted using acrimper. Then, a tow was cut such that a length of the single fiber was20 mm. Accordingly, an acrylic short fiber in which a cross-sectionalshape was approximately a broad bean shape and single fiber fineness was1 dtex was obtained.

Thereafter, as shown in Table 1 below, 20% by mass of the acrylic fiberin which the cross-sectional shape was a broad bean shape and 30% bymass of the acrylic fiber in which the cross-sectional shape was acircular shape, 30% by mass of the polyester fiber of Example 3 in whichthe cross-sectional shape was hollow, and 20% by mass of the polyesterfiber of Example 2 in which the cross-sectional shape was circular weremixed with a cotton mixing machine to pass through a spreading machine,and further mixed with a carding machine to obtain the wadding.

Then, bulkiness evaluation and warmth retention property evaluation wereperformed using the obtained wadding by the same method as above. Theevaluation results are shown in Table 1 below.

Comparative Example 1

The bulkiness and the warmth retention property of anothermanufacturer's product (product name: PrimaLoft (registered trademark),manufactured by Albany International Corp., and polyester 100%) used forthe wadding were evaluated by the same method as above. The resultsthereof are shown in Table 1 below.

The PrimaLoft used in Comparative Example 1 is formed of polyesterhaving single fiber fineness of 1 dtex. Instead of several kinds ofpolyesters having different fineness being mixed as in the presentinvention. PrimaLoft is formed of only a fiber having singular fineness.

Comparative Example 2

The bulkiness and the warmth retention property of anothermanufacturer's product (product name: Air Flake (registered trademark),manufactured by KURABO INDUSTRIES LTD.) used for the wadding wereevaluated by the same method as above. The results thereof are shown inTable 1 below.

The wadding of Comparative Example 2 is formed of a long fiber andincludes a core yarn and a fancy yarn, in which the fancy yarn is longerthan the core yarn, the core yarn and the fancy yarn are united byinterlacing, the fancy yarn is interlacing yarn for wadding which isopened to form a loop-shaped fiber, the fancy yarn is hollow fiber, anda hollow ratio is 25%. In addition, in the wadding material ofComparative Example 2, both the core yarn and the fancy yarn are 100% bymass of polyester fibers.

Comparative Example 3

100% by mass of the polyester fiber having a circular cross section(single fiber fineness: 1.7 dtex and fiber length: 15 mm) was passedthrough a spreading machine and then further wadding was stirred withair to obtain the wadding. Thereafter, the bulkiness and the warmthretention property thereof were evaluated by the same method as above.The evaluation results thereof are shown in Table 1 below.

The wadding obtained in Comparative Example 3 was low both in thebulkiness and the warmth retention property.

Comparative Example 4

100% by mass of the polyester fiber having the hollow cross section(fiber fineness: 2.2 dtex and fiber length: 20 mm) used in Example 1 wasused to pass through the spreading machine and then further wadding wasstirred with air to obtain the wadding. The evaluation results thereofare shown in Table 1.

The obtained wadding was low in both bulkiness and the warmth retentionproperty.

Reference Example 1

100% by mass of the acrylic fiber (single fiber fineness: 0.8 dtex andfiber length: 38 mm) used in Example 1 was used to pass through thespreading machine and then mixed with the carding machine to obtain thewadding.

The wadding obtained above was used for performing the bulkinessevaluation and the warmth retention property evaluation by the samemethod as above. The evaluation results are shown in Table 1 below.

Reference Example 1 was a wadding of 100% by mass of the acrylic fiber,in which the down power and the Clo value were favorable but thepermanent setting property was inferior.

TABLE 1 Compar- Compar- Compar- Compar- Example Example Example Exampleative ative ative ative Reference 1 2 3 4 Example 1 Example 2 Example 3Example 4 Example 1 <Fiber 1> Kind of fiber Acryl Acryl Acryl AcrylPolyester Polyester Polyester Polyester Acryl Cross-sectional CircularCircular Circular Circular Circular Circular Circular Hollow Circularshape shape shape shape shape shape shape shape shape shape Fineness(dtex) 0.8 0.8 0.8 1 1 1.2 1.7 2.2 0.8 Fiber length (mm) 38 38 38 20 50— 15 20 38 Number of crimps 12 12 12 12 10 10 10 10 10 (peaks/25 mm)Mixing ratio (%) 60 60 80 30 100 40 100 100 100 <Fiber 2> Kind of fiberPolyester Polyester Polyester Acryl — Polyester — — — Cross-sectionalHollow Circular Hollow Broad — Hollow — — — shape shape shape shape beanshape shape Fineness (dtex) 2.2 1.7 2.2 2.2 — 1.7 — — — Fiber length(mm) 20 15 20 20 — 50 — — — Number of crimps 10 10 10 12 — 10 — — —(peaks/25 min) Mixing ratio (%) 40 40 20 20 — 60 — — — <Fiber 3> Kind offiber — — — Polyester — — — — — Cross-sectional — — — Hollow — — — — —shape shape Fineness (dtex) — — — 2.2 — — — — — Fiber length (mm) — — —20 — — — — — Number of crimps — — — 10 — — — — — (peaks/25 mm) Mixingratio (%) — — — 30 — — — — — >Fiber 4> Kind of fiber — — — Polyester — —— — — Cross-sectional — — — Circular — — — — — shape shape Fineness(dtex) — — — 1.7 — — — — — Fiber length (mm) — — — 15.0 — — — — — Numberof crimps — — — 10 — — — — — (peaks/25 mm) Mixing ratio (%) — — — 20 — —— — — >Wadding> Shape Wadding Wadding Wadding Wadding Wadding YarnWadding Wadding Wadding shape shape shape shape shape shape shape shapeshape Down power (cm³/g) 191 195 197 179 137 206 99 142 219 clo value4.07 4.14 4.56 4.28 3.87 3.64 2.6 3.12 4.12 Permanent setting B B B B AA A A C property

Example 5

A copolymer formed of 93% by mass of acrylonitrile and 7% by mass ofvinyl acetate was dissolved in dimethylacetamide such that theconcentration of the copolymer was 24% by mass. Thereafter, the solutionwas discharged into an aqueous solution including 50% by mass ofdimethylacetamide using a nozzle having a round discharge hole with ahole diameter of 0.060 mm and subjected to washing in boiling water andstretching to 6 times. Then, an oil agent was applied to be dried at atemperature of 150° C. Thereafter, a thermal relaxation treatment wascarried out and mechanical crimp of 12 peaks/25 mm was imparted using acrimper. A tow was cut such that a length of the single fiber was 20 mm.Accordingly, an acrylic short fiber in which single fiber fineness was1.0 dtex and a cross-sectional shape perpendicular to a fiber axisdirection was a circular shape was obtained.

Thereafter, 50% by mass of the acrylic short fibers as a fiber 1 and 50%by mass of the polyester fiber (single fiber fineness: 2.5 dtex andfiber length: 32 mm) as a fiber 2 were mixed to pass through a cottongranulator, thereby obtaining granular wadding.

Then, bulkiness evaluation and warmth retention property evaluation wereperformed using the obtained wadding by the same method as above. Theevaluation results thereof are shown in Table 2 below.

Example 6

The wadding was manufactured and evaluated by the same method as inExample 5 except that the acrylic short fiber of the fiber 1 was changedto those described in Table 2 below.

The evaluation results of bulkiness and the warmth retention property ofthe obtained wadding are shown in Table 2 below.

Comparative Example 5

The wadding was manufactured and evaluated by the same method as inExample 5 except that the acrylic short fiber of the fiber 1 was changedto those described in Table 2 below.

The evaluation results of the bulkiness and the warmth retentionproperty of the obtained wadding are shown in Table 2 below.

The obtained wadding of Comparative Example 5 was low in down power.

Comparative Example 6

The granular wadding was manufactured and evaluated by the same methodas in Example 5 except that the acrylic short fiber of the fiber 1 waschanged to a flat acrylic short fiber in which single fiber fineness was17 dtex, a cross-sectional shape perpendicular to the fiber axisdirection was a flat shape, and a flatness ratio was 10.

The evaluation results of the bulkiness and the warmth retentionproperty of the obtained wadding are shown in Table 2 below.

The obtained wadding of Comparative Example 6 was low in the Clo value.

Comparative Example 7

The granular wadding was manufactured and evaluated by the same methodas in Example 5 except that the fiber 1 was changed to the flat acrylicshort fiber used in Comparative Example 6 and the fiber 2 was changed tothe acrylic short fiber used in Example 3.

The evaluation results of the bulkiness and the warmth retentionproperty of the obtained wadding are shown in Table 2 below.

The obtained wadding of Comparative Example 7 was low in down power andClo value and poor in permanent setting property.

Comparative Example 8

The granular wadding was manufactured and evaluated by the same methodas in Example 1 except that the fiber 2 was changed to the same fiber asfiber 1 used in Example 6.

The evaluation results of the bulkiness and the warmth retentionproperty of the obtained wadding are shown in Table 2 below.

The obtained wadding of Comparative Example 8 was low in Clo value andpoor in permanent setting property.

TABLE 2 Compar- Compar- Compar- Compar- Example Example ative ativeative ative 5 6 Example 5 Example 6 Example 7 Example 8 <Fiber 1> Kindof fiber Acryl Acryl Acryl Acryl Acryl Acryl Cross-sectional CircularEllipse Broad bean Flat Flat Circular shape shape shape shape shapeshape shape Fineness (dtex) 1 6.6 2.2 17 17 1 Fiber length (mm) 20 32 3232 32 20 Number of crimps 12 12 12 12 12 12 (peaks/25 mm) Mixing ratio(%) 50 50 50 50 50 50 <Fiber 2> Kind of fiber Polyester PolyesterPolyester Polyester Acryl Acryl Cross-sectional Circular CircularCircular Circular Circular Ellipse shape shape shape shape shape shapeshape Fineness (dtex) 2.5 2.5 2.5 2.5 1 6.6 Fiber length (mm) 32 32 3232 20 32 Number of crimps 10 10 10 10 12 12 (peaks/25 mm) Mixing ratio(%) 50 50 50 50 50 50 <Fiber 3> Kind of fiber — — — — — —Cross-sectional — — — — — — shape Fineness (dtex) — — — — — — Fiberlength (mm) — — — — — — Number of crimps — — — — — — (peaks/25 mm)Mixing ratio (%) — — — — — — <Fiber 4> Kind of fiber — — — — — —Cross-sectional — — — — — — shape Fineness (dex) — — — — — — Fiberlength (mm) — — — — — — Number of crimps — — — — — — (peaks/25 mm)Mixing ratio (%) — — — — — — <Wadding> Shape Granular Granular GranularGranular Granular Granular wadding wadding wadding wadding waddingwadding shape shape shape shape shape shape Maximum length of 10 10 1010 10 10 granular wadding (mm) Down power 153 152 126 156 129 134(cm³/g) clo value 3.88 3.90 3.79 3.20 3.36 3.81 Permanent setting B B BB C C property

1. A wadding that is obtained by mixing 20% by mass or more and 95% bymass or less of an acrylic fiber and 5% by mass or more and 80% by massor less of a polyester fiber, wherein a down power is 140 cm³/g or moreand 300 cm³/g or less, and a Clo value is 3.7 or more and 5 or less. 2.The wadding according to claim 1, wherein single fiber fineness of theacrylic fiber is 0.1 dtex or more and 10 dtex or less, and single fiberfineness of the polyester fiber is 1.0 dtex or more and 10 dtex or less.3. The wadding according to claim 1, wherein the polyester fiber is ahollow fiber, and a hollow ratio of the hollow fiber is 10% or more and30% or less.
 4. The wadding according to claim 1, wherein the down poweris 150 cm³/g or more and 280 cm³/g or less.
 5. The wadding according toclaim 1, wherein the down power is 160 cm³/g or more and 200 cm³/g orless.
 6. The wadding according to claim 1, wherein the Clo value is 3.8or more and 4.8 or less.
 7. The wadding according to claim 1, whereinthe Clo value is 4 or more and 4.7 or less.
 8. The wadding according toclaim 1, wherein the single fiber fineness of the acrylic fiber is 0.5dtex or more and 2.2 dtex or less, and the single fiber fineness of thepolyester fiber is 1.7 dtex or more and 2.2 dtex or less.
 9. The waddingaccording to claim 1, wherein a fiber length of the acrylic fiber is 15mm or more and 40 mm or less, and a fiber length of the polyester fiberis 10 mm or more and 40 mm or less.
 10. The wadding according to claim1, wherein a mixing ratio of a heat-bonding short fiber with respect tothe wadding is 5% by mass or more and 30% by mass or less, and at leasta part of the heat-bonding short fiber is bonded to the acrylic fiber orthe polyester fiber.
 11. The wadding according to claim 1, wherein 30%by mass or more and 70% by mass or less of the acrylic fiber and 30% bymass or more and 70% by mass or less of the polyester fiber are mixed,and the wadding is granular wadding in which one or a plurality offibers are intertwined.
 12. The wadding according to claim 11, whereinthe polyester fiber is a conjugate fiber and has a coil-like form in ano-load state.
 13. The wadding according to claim 11, wherein themaximum length of the granular wadding is 2 mm or more and 20 mm orless.
 14. The wadding according to claim 1, wherein the number of crimpsof the acrylic fiber is 3 peaks/25 mm or more and 20 peaks/25 mm orless.
 15. The wadding according to claim 1, wherein a decreasing rate ofthe down power after washing 10 times is 30% or lower.